Connection structures for intravascular devices and associated systems and methods

ABSTRACT

Intravascular devices, systems, and methods are disclosed. In some embodiments, a method of assembling an intravascular device is provided that includes positioning a first tubular member around a plurality of conductors and a core member; advancing a first of the plurality of conductors through an opening of the first tubular member; positioning a first conductive member around the first tubular member; and electrically coupling the first of the plurality of conductors to the first conductive member. In some embodiments, an intravascular device is provided that includes an insulating member positioned around a plurality of conductors and a core member and a conductive member positioned around the insulating member, wherein at least one of the plurality of conductors extends through an opening in the insulating member and is electrically coupled to the first conductive member.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority to and the benefit of U.S.Provisional Patent Application No. 61/665,711, filed Jun. 28, 2012,which is hereby incorporated by reference herein in its entirety.

TECHNICAL FIELD

The present disclosure relates to intravascular devices, systems, andmethods. In some embodiments, the intravascular devices are guidewiresthat include one or more electronic components.

BACKGROUND

Heart disease is very serious and often requires emergency operations tosave lives. A main cause of heart disease is the accumulation of plaqueinside the blood vessels, which eventually occludes the blood vessels.Common treatment options available to open up the occluded vesselinclude balloon angioplasty, rotational atherectomy, and intravascularstents. Traditionally, surgeons have relied on X-ray fluoroscopic imagesthat are planar images showing the external shape of the silhouette ofthe lumen of blood vessels to guide treatment. Unfortunately, with X-rayfluoroscopic images, there is a great deal of uncertainty about theexact extent and orientation of the stenosis responsible for theocclusion, making it difficult to find the exact location of thestenosis. In addition, though it is known that restenosis can occur atthe same place, it is difficult to check the condition inside thevessels after surgery with X-ray.

A currently accepted technique for assessing the severity of a stenosisin a blood vessel, including ischemia causing lesions, is fractionalflow reserve (FFR). FFR is a calculation of the ratio of a distalpressure measurement (taken on the distal side of the stenosis) relativeto a proximal pressure measurement (taken on the proximal side of thestenosis). FFR provides an index of stenosis severity that allowsdetermination as to whether the blockage limits blood flow within thevessel to an extent that treatment is required. The normal value of FFRin a healthy vessel is 1.00, while values less than about 0.80 aregenerally deemed significant and require treatment.

Often intravascular catheters and guidewires are utilized to measure thepressure within the blood vessel. To date, guidewires containingpressure sensors or other electronic components have suffered fromreduced performance characteristics compared to standard guidewires thatdo not contain electronic components. For example, the handlingperformance of previous guidewires containing electronic components havebeen hampered, in some instances, by the limited space available for thecore wire after accounting for the space needed for the conductors orcommunication lines of the electronic component(s), the stiffness of therigid housing containing the electronic component(s), and/or otherlimitations associated with providing the functionality of theelectronic components in the limited space available within a guidewire.Further, due to its small diameter, in many instances the proximalconnector portion of the guidewire (i.e., the connector(s) thatfacilitate communication between the electronic component(s) of theguidewire and an associated controller or processor) is fragile andprone to kinking, which destroys the functionality of the guidewire. Forthis reason, surgeons are reluctant to remove the proximal connectorfrom the guidewire during a procedure for fear of breaking the guidewirewhen reattaching the proximal connector. However, having the guidewirecoupled to the proximal connector further limits the maneuverability andhandling of the guidewire.

Accordingly, there remains a need for improved connectors and connectorportions for use with intravascular devices (e.g., catheters andguidewires) that include one or more electronic components.

SUMMARY

Embodiments of the present disclosure are directed to intravasculardevices, systems, and methods.

In some embodiments, methods of assembling an intravascular device areprovided. In one embodiment, the method includes positioning a firsttubular member around a plurality of conductors and a core member suchthat the plurality of conductors and the core member are at leastpartially positioned within a lumen of the first tubular member, thefirst tubular member including an opening extending along a length ofthe first tubular member in communication with the lumen; advancing afirst of the plurality of conductors through the opening of the firsttubular member; positioning a first conductive member around the firsttubular member; and electrically coupling the first of the plurality ofconductors to the first conductive member. In some instances, the methodfurther includes positioning a first insulating member around the firsttubular member adjacent to the first conductive member; positioning asecond conductive member around the first tubular member adjacent to thefirst insulating member such that the first insulating member ispositioned between the first and second conductive members; andelectrically coupling a second of the plurality of conductors to thesecond conductive member. In that regard, the second of the plurality ofconductors is advanced through the opening of the first tubular memberin some instances.

In some embodiments, an intravascular device is provided. In oneembodiment, the intravascular device includes a tubular memberpositioned around a plurality of conductors and a core member such thatthe plurality of conductors and the core member are at least partiallypositioned within a lumen of the tubular member, the tubular memberincluding an opening extending along a length of the tubular member incommunication with the lumen; a first conductive member positionedaround the tubular member, wherein a first of the plurality ofconductors extends through the opening in the tubular member and iselectrically coupled to the first conductive member; a first insulatingmember positioned around the tubular member adjacent to the firstconductive member; and a second conductive member positioned around thetubular member adjacent to the first insulating member such that thefirst insulating member is positioned between the first and secondconductive members, wherein a second of the plurality of conductors iselectrically coupled to the second conductive member. In some instances,the opening extends along an entire length of the tubular member. Inother instances, the opening extends along only a portion of the lengthof the tubular member. In some implementations, the intravascular deviceincludes a second insulating member positioned around the tubular memberadjacent to the second conductive member and a third conductive memberpositioned around the tubular member adjacent to the second insulatingmember such that the second insulating member is positioned between thesecond and third conductive members.

In another embodiment, the intravascular device includes a firstinsulating member positioned around a plurality of conductors and a coremember such that the plurality of conductors and the core member are atleast partially positioned within a lumen of the first insulatingmember, the first insulating member having a first portion with a firstdiameter, a second portion with a second diameter less than the firstdiameter, and an opening extending along a length of the firstinsulating member in communication with the lumen; and a firstconductive member positioned around the second portion of the firstinsulating member, wherein a first of the plurality of conductorsextends through the opening in the first insulating member and iselectrically coupled to the first conductive member. In some instances,the opening of the first insulating member extends along only a portionof the length of the first insulating member. In some particularinstances, the opening of the first insulating member extends along thesecond portion of the first insulating member. In some embodiments, thefirst conductive member has an outer diameter equal to the firstdiameter.

Additional aspects, features, and advantages of the present disclosurewill become apparent from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

Illustrative embodiments of the present disclosure will be describedwith reference to the accompanying drawings, of which:

FIG. 1 is a diagrammatic perspective view of an intravascular systemaccording to an embodiment of the present disclosure.

FIG. 2 is a diagrammatic side view of an intravascular device of theintravascular system of FIG. 1 according to an embodiment of the presentdisclosure.

FIG. 3 is a diagrammatic side view of a proximal connector portion ofthe intravascular device of FIG. 2 according to an embodiment of thepresent disclosure.

FIG. 4 is a diagrammatic side view of a proximal connector portion of anintravascular device of FIG. 2 similar to that of FIG. 3, butillustrating another embodiment of the present disclosure.

FIG. 5 is a diagrammatic side view of an intravascular device of theintravascular system of FIG. 1 similar to that of FIG. 2, butillustrating another embodiment of the present disclosure.

FIG. 6 is a diagrammatic side view of a proximal connector portion ofthe intravascular device of FIG. 5 according to an embodiment of thepresent disclosure.

FIG. 7 is a diagrammatic side view of a proximal connector portion of anintravascular device of FIG. 5 similar to that of FIG. 6, butillustrating another embodiment of the present disclosure.

FIG. 8 is a diagrammatic side view of a proximal connector portion of anintravascular device according to an embodiment of the presentdisclosure.

FIG. 9 is a diagrammatic partial cross-sectional side view of theproximal connector portion of FIG. 8.

FIG. 10 is a diagrammatic side view of a component of the proximalconnector portion of FIGS. 8 and 9 according to an embodiment of thepresent disclosure.

FIG. 11 is a diagrammatic side view of a component of the proximalconnector portion of FIGS. 8 and 9 similar to that of FIG. 10, butillustrating another embodiment of the present disclosure.

FIG. 12 is a diagrammatic side view of a component of the proximalconnector portion of FIGS. 8 and 9 similar to that of FIGS. 10 and 11,but illustrating yet another embodiment of the present disclosure.

Collectively, FIGS. 13-19 illustrate various aspects of assembling aproximal connector portion as illustrated in FIGS. 8 and 9 according toan exemplary embodiment of the present disclosure.

FIG. 13 is a diagrammatic cross-sectional side view showing a component,such as one of the components of FIGS. 10-12, being positioned over acore wire and a plurality of conductors.

FIG. 14 is a diagrammatic cross-sectional side view showing aninsulating element being positioned over the component of FIG. 13.

FIG. 15 is a diagrammatic cross-sectional side view showing one of theplurality of conductors being passed through an opening the component ofFIG. 13 adjacent to the insulating element of FIG. 14.

FIG. 16 is a diagrammatic cross-sectional side view showing a conductiveelement being positioned over the component of FIG. 13 and electricallycoupled to the conductor that was passed through the opening in thecomponent in FIG. 15.

FIG. 17 is a diagrammatic cross-sectional side view showing anotherinsulating element being positioned over the component of FIG. 13 andpositioned adjacent to the conductive element of FIG. 16.

FIG. 18 is a diagrammatic cross-sectional side view showing another ofthe plurality of conductors being passed through an opening thecomponent of FIG. 13 adjacent to the insulating element of FIG. 17.

FIG. 19 is a diagrammatic cross-sectional side view showing anotherconductive element being positioned over the component of FIG. 13 andelectrically coupled to the conductor that was passed through theopening in the component as shown in FIG. 18.

FIG. 20 is a diagrammatic side view of a proximal connector portion ofan intravascular device according to another embodiment of the presentdisclosure.

FIG. 21 is a diagrammatic side view of a portion of the proximalconnector portion of FIG. 20 with inner components of the proximalconnector portion illustrated.

FIG. 22 is a close-up diagrammatic side view of a portion of theproximal connector portion of FIGS. 20 and 21 with inner components ofthe proximal connector portion illustrated.

FIG. 23 is a diagrammatic side view of an element for forming acomponent of the proximal connector portion of FIGS. 20-22 according toan embodiment of the present disclosure.

FIG. 24 is a diagrammatic side view of the element of FIG. 23 withmarkings showing portions of the element that will be removed to form acomponent of the proximal connector portion of FIGS. 20-22 according toan embodiment of the present disclosure.

FIG. 25 is a diagrammatic side view of a component of the proximalconnector portion of FIGS. 20-22 formed from the element of FIG. 23according to the markings shown in FIG. 24.

FIG. 26 is a diagrammatic side view of the element of FIG. 23 withmarkings showing portions of the element that will be removed to form acomponent of the proximal connector portion of FIGS. 20-22 according toanother embodiment of the present disclosure.

FIG. 27 is a diagrammatic side view of a component of the proximalconnector portion of FIGS. 20-22 formed from the element of FIG. 23according to the markings shown in FIG. 26.

FIG. 28 is a diagrammatic side view of a component of the proximalconnector portion of FIGS. 20-22 formed from the element of FIG. 23according to another embodiment of the present disclosure.

Collectively, FIGS. 29-34 illustrate various aspects of assembling aproximal connector portion similar to the embodiment illustrated inFIGS. 20-22 according to an exemplary embodiment of the presentdisclosure.

FIG. 29 is a diagrammatic cross-sectional side view showing a component,such as one of the components of FIGS. 25, 27, and/or 28, beingpositioned over a core wire and a plurality of conductors.

FIG. 30 is a diagrammatic cross-sectional side view showing one of theplurality of conductors being passed through an opening the component ofFIG. 29 and positioned adjacent to an insulating element defined by thecomponent.

FIG. 31 is a diagrammatic cross-sectional side view showing a conductiveelement being positioned over a portion of the component of FIG. 29 andelectrically coupled to the conductor that was passed through theopening in the component in FIG. 30.

FIG. 32 is a diagrammatic cross-sectional side view showing anothercomponent, such as one of the components of FIGS. 25, 27, and/or 28,being positioned adjacent to the conductive element of FIG. 31 such thata portion of the conductive element is positioned over the component.

FIG. 33 is a diagrammatic cross-sectional side view showing another ofthe plurality of conductors being passed through an opening thecomponent of FIG. 32 and positioned adjacent to an insulating elementdefined by the component.

FIG. 34 is a diagrammatic cross-sectional side view showing anotherconductive element being positioned over a portion of the component ofFIG. 32 and electrically coupled to the conductor that was passedthrough the opening in the component in FIG. 33.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles of thepresent disclosure, reference will now be made to the embodimentsillustrated in the drawings, and specific language will be used todescribe the same. It is nevertheless understood that no limitation tothe scope of the disclosure is intended. Any alterations and furthermodifications to the described devices, systems, and methods, and anyfurther application of the principles of the present disclosure arefully contemplated and included within the present disclosure as wouldnormally occur to one skilled in the art to which the disclosurerelates. In particular, it is fully contemplated that the features,components, and/or steps described with respect to one embodiment may becombined with the features, components, and/or steps described withrespect to other embodiments of the present disclosure. For the sake ofbrevity, however, the numerous iterations of these combinations will notbe described separately.

As used herein, “flexible elongate member” or “elongate flexible member”includes at least any thin, long, flexible structure that can beinserted into the vasculature of a patient. While the illustratedembodiments of the “flexible elongate members” of the present disclosurehave a cylindrical profile with a circular cross-sectional profile thatdefines an outer diameter of the flexible elongate member, in otherinstances all or a portion of the flexible elongate members may haveother geometric cross-sectional profiles (e.g., oval, rectangular,square, elliptical, etc.) or non-geometric cross-sectional profiles.Flexible elongate members include, for example, intravascular cathetersand intravascular guidewires. In that regard, intravascular cathetersmay or may not include a lumen extending along its length for receivingand/or guiding other instruments. If the intravascular catheter includesa lumen, the lumen may be centered or offset with respect to thecross-sectional profile of the device.

In most embodiments, the flexible elongate members of the presentdisclosure include one or more electronic, optical, or electro-opticalcomponents. For example, without limitation, a flexible elongate membermay include one or more of the following types of components: a pressuresensor, a temperature sensor, an imaging element, an optical fiber, anultrasound transducer, a reflector, a minor, a prism, an ablationelement, an fro electrode, a conductor, and/or combinations thereof.Generally, these components are configured to obtain data related to avessel or other portion of the anatomy in which the flexible elongatemember is disposed. Often the components are also configured tocommunicate the data to an external device for processing and/ordisplay. In some aspects, embodiments of the present disclosure includeimaging devices for imaging within the lumen of a vessel, including bothmedical and non-medical applications. However, some embodiments of thepresent disclosure are particularly suited for use in the context ofhuman vasculature. Imaging of the intravascular space, particularly theinterior walls of human vasculature can be accomplished by a number ofdifferent techniques, including ultrasound (often referred to asintravascular ultrasound (“IVUS”) and intracardiac echocardiography(“ICE”)) and optical coherence tomography (“OCT”). In other instances,infrared, thermal, or other imaging modalities are utilized. Further, insome instances the flexible elongate member includes multipleelectronic, optical, and/or electro-optical components (e.g., pressuresensors, temperature sensors, imaging elements, optical fibers,ultrasound transducers, reflectors, mirrors, prisms, ablation elements,fro electrodes, conductors, etc.).

The electronic, optical, and/or electro-optical components of thepresent disclosure are often disposed within a distal portion of theflexible elongate member. As used herein, “distal portion” of theflexible elongate member includes any portion of the flexible elongatemember from the mid-point to the distal tip. As flexible elongatemembers can be solid, some embodiments of the present disclosure willinclude a housing portion at the distal portion for receiving theelectronic components. Such housing portions can be tubular structuresattached to the distal portion of the elongate member. Some flexibleelongate members are tubular and have one or more lumens in which theelectronic components can be positioned within the distal portion.

The electronic, optical, and/or electro-optical components and theassociated communication lines are sized and shaped to allow for thediameter of the flexible elongate member to be very small. For example,the outside diameter of the elongate member, such as a guidewire orcatheter, containing one or more electronic, optical, and/orelectro-optical components as described herein are between about 0.0007″(0.0178 mm) and about 0.118″ (3.0 mm), with some particular embodimentshaving outer diameters of approximately 0.014″ (0.3556 mm) andapproximately 0.018″ (0.4572 mm). As such, the flexible elongate membersincorporating the electronic, optical, and/or electro-opticalcomponent(s) of the present application are suitable for use in a widevariety of lumens within a human patient besides those that are part orimmediately surround the heart, including veins and arteries of theextremities, renal arteries, blood vessels in and around the brain, andother lumens.

“Connected” and variations thereof as used herein includes directconnections, such as being glued or otherwise fastened directly to, on,within, etc. another element, as well as indirect connections where oneor more elements are disposed between the connected elements.

“Secured” and variations thereof as used herein includes methods bywhich an element is directly secured to another element, such as beingglued or otherwise fastened directly to, on, within, etc. anotherelement, as well as indirect techniques of securing two elementstogether where one or more elements are disposed between the securedelements.

Referring now to FIG. 1, shown therein is an intravascular system 100according to an embodiment of the present disclosure. In that regard,the intravascular system includes an intravascular device 102 and aconnector 104. Referring now to FIG. 2, a side view of the intravasculardevice 102 is provided according to an embodiment of the presentdisclosure. As shown, the intravascular device 102 includes a flexibleelongate member 106 having a distal portion 107 adjacent a distal end108 and a proximal portion 109 adjacent a proximal end 110. A component112 is positioned within the distal portion 107 of the flexible elongatemember 106 proximal of the distal tip 108. Generally, the component 112is representative of one or more electronic, optical, or electro-opticalcomponents. In that regard, the component 112 is a pressure sensor, atemperature sensor, an imaging element, an optical fiber, an ultrasoundtransducer, a reflector, a minor, a prism, an ablation element, an froelectrode, a conductor, and/or combinations thereof. The specific typeof component or combination of components can be selected based on anintended use of the intravascular device. In some instances, thecomponent 112 is positioned less than 10 cm, less than 5, or less than 3cm from the distal tip 108. In some instances, the component 112 ispositioned within a housing of the intravascular device 102. In thatregard, the housing is a separate component secured to the flexibleelongate member 106 in some instances. In other instances, the housingis integrally formed as a part of the flexible elongate member 106. Insome embodiments, the flexible elongate member 106 comprises a stainlesssteel hypotube. Further, in some embodiments all or a portion of theflexible elongate member 106 is covered with a hydrophilic orhydrophobic coating. In some particular embodiments, apolytetrafluoroethylene (PTFE) coating is utilized.

The intravascular device 102 also includes a connection portion 114adjacent the proximal portion 109 of the device. In that regard, theconnection portion 114 is spaced from the proximal end 110 of theflexible elongate member 106 by a distance 116. Generally, the distance116 is between 0% and 50% of the total length of the flexible elongatemember 106. While the total length of the flexible elongate member canbe any length, in some embodiments the total length is between about1300 mm and about 4000 mm, with some specific embodiments having alength of 1400 mm, 1900 mm, and 3000 mm. In some instances theconnection portion 114 is spaced from the proximal end 110 between about0 mm and about 1400 mm. In some specific embodiments, the connectionportion 114 is spaced from the proximal end by a distance of 0 mm, 300mm, and 1400 mm. Accordingly, in some instances the connection portion114 is positioned at the proximal end 110. In some such embodiments, oneor more aspects of the engagement and alignment features of theintravascular device 102 discussed below are positioned distal of the ofthe connection portion 114 instead of proximal of the connection portion114 as shown in the embodiment of FIG. 2.

In that regard, in the illustrated embodiment of FIG. 2 theintravascular device 102 includes a section 118 extending proximallyfrom the connection portion 114 to another section 120 that extends toproximal end 110. In the illustrated embodiment, the section 120 isrounded to proximal end 110. In other embodiments, the section 120 has atapered, arcuate, and/or other changing profile as it extends proximallyto proximal end 110. In that regard, in some instances the outer profileand/or diameter of the section 120 reduces as it extends proximally toproximal end 110 such that the reduced profile and/or diameter of theproximal end facilitates easier introduction of one or more otherinstruments over the intravascular device. In other embodiments, thesection 120 has a constant profile as it extends proximally to proximalend 120.

As shown, the connection portion 114 has a diameter 122 (or othersimilar measurement for outer cross-section profiles for non-circularcross-sectional embodiments) while section 118 has a diameter 124(again, or other similar measurement for outer cross-section profilesfor non-circular cross-sectional embodiments). The diameter 124 ofsection 118 is different than the diameter 122 of connection portion114. In that regard, the different sizes of the diameters 122, 124creates a structure that is configured to facilitate alignment and/orconnection of the intravascular device 102 to a connector, such asconnector 104. In the illustrated embodiment, the diameter 124 ofsection 118 is less than the diameter 122 of the connection portion 114.In some embodiments, the diameter 124 of section 118 is between about40% and about 80% of diameter 122, with some particular embodimentsbeing about 42%, 64%, and/or other percentage of diameter 122. In thatregard, in some embodiments the diameter 122 of connection portion 114is between about 0.0178 mm and about 3.0 mm, with some particularembodiments being 0.3556 mm (0.014″) and 0.4572 mm (0.018″).Accordingly, in some embodiments the diameter 124 of section 118 isbetween about 0.007 mm and about 2.4 mm, with some particularembodiments being 0.15 mm, 0.19 mm, 0.23 mm, and 0.29 mm. In theillustrated embodiment, the section 120 has a diameter that isapproximately equal to diameter 122 and, therefore, greater thandiameter 124. However, in other embodiments, section 120 has a diameterthat is greater than diameter 122, less than diameter 122, greater thandiameter 124, equal to diameter 124, and/or less than diameter 124. Insome embodiments, section 118 is a section of a core wire extendingthrough the connection portion 114.

As shown in FIG. 2, the section 118 extends proximally from connectionportion 114 a distance 126, while section 120 extends proximally fromsection 118 to proximal end 110 a distance 128. Together, distances 126and 128 equal the distance 116 that the connection portion 114 is spacedfrom the proximal end 110 of the intravascular device 102. In someinstances, the distance 126 of is between about 0.508 mm (0.020″) andabout 2.54 mm (0.10″), with some particular embodiments being 0.762 mm(0.030″), 1.016 mm (0.040″), and 1.524 mm (0.060″). Further, while thetransition between connection portion 114 and section 118 and thetransition between section 118 and section 120 are shown as beingstepped in the illustrated embodiments, in other embodiments thetransitions are tapered and/or otherwise make a gradual change in outerdiameter along the length of the intravascular device. In someembodiments, use of tapered and/or gradual transitions results in theproximal portion of the intravascular device 102 not having any sharpedges. In some implementations, the use of tapered and/or gradualtransitions for one or both of the transitions between section 118 andeither the connection portion 114 or section 120 makes cleaning theproximal portion of the device (e.g., to remove any liquids or otherunwanted materials on the surface of the proximal portion of theintravascular device) easier. In some instances, sections 118 and 120are formed as a separate assembly or component and subsequently joinedto the connection portion 114 via suitable techniques, such as usingsolder, adhesive, mechanical connections, and/or combinations thereof.

The connection portion 114 is configured to facilitate communicationbetween the intravascular device 102 and another device. Morespecifically, in some embodiments the connection portion 114 isconfigured to facilitate communication of data obtained by the component112 to another device, such as a computing device or processor.Accordingly, in some embodiments the connection portion 114 is anelectrical connector. In such instances, the connection portion 114 isconfigured to provide an electrical connection to one or more electricalconductors that extend along the length of the flexible elongate member102 and are electrically coupled to the component 112. In someinstances, the connection portion 114 includes one or more electricalconnectors as described in U.S. Patent Application Ser. No. 61/665,697,titled “INTRAVASCULAR DEVICES, SYSTEMS, AND METHODS,” filed Jun. 28,2012, which is hereby incorporated by reference in its entirety. Inother embodiments, the connection portion 114 includes an opticalconnector. In such instances, the connection portion 114 provides anoptical connection to one or more optical communication pathways (e.g.,fiber optic cable) that extend along the length of the flexible elongatemember 106 and are optically coupled to the component 112. Further, insome embodiments the connection portion 114 provides both electrical andoptical connections to both electrical conductor(s) and opticalcommunication pathway(s) coupled to the component 112. In that regard,it should again be noted that component 112 is comprised of a pluralityof elements in some instances. In some instances, the connection portion114 is configured to provide a physical connection to another device,either directly or indirectly. In other instances, the connectionportion 114 is configured to facilitate wireless communication betweenthe intravascular device 102 and another device. Generally, any currentor future developed wireless protocol(s) may be utilized. In yet otherinstances, the connection portion 114 facilitates both physical andwireless connection to another device.

As noted above, in some instances the connection portion 114 provides aconnection between the component 112 of the intravascular device 102,120 and an external device. Accordingly, in some embodiments one or moreelectrical conductors, one or more optical pathways, and/or combinationsthereof extend along the length of the flexible elongate member 106between the connection portion 114 and the component 112 to facilitatecommunication between the connection portion 114 and the component 112.Generally, any number of electrical conductors, optical pathways, and/orcombinations thereof can extend along the length of the flexibleelongate member 106 between the connection portion 114 and the component112. In some instances, between one and ten electrical conductors and/oroptical pathways extend along the length of the flexible elongate member106 between the connection portion 114 and the component 112. For thesake of clarity and simplicity, the embodiments of the presentdisclosure described below include three electrical conductors and,therefore, the connection portion 114 is described as having threeseparate electrical connections corresponding to the three electricalconductors.

For example, as shown in FIG. 3, in some instances the connectionportion 114 includes conductive portions 132, 134, and 136 that areseparated from one another and the main body of the flexible elongatemember 106 by insulating portions 138, 140, 142, and 144. In thatregard, the conductive portions 132, 134, and 136 are formed of aconductive material and are portions of a hypotube, a coil, and/orcombinations thereof in some instances. It is understood that the totalnumber of communication pathways and/or the number of electricalconductors and/or optical pathways is different in other embodimentsand, therefore, the number of conductive portions (or opticalconnectors) included in connection portion is different as well. Morespecifically, the number of communication pathways and the number ofelectrical conductors and optical pathways extending along the length ofthe flexible elongate member 106 is determined by the desiredfunctionality of the component 112 and the corresponding elements thatdefine component 112 to provide such functionality. As a result, thenumber and type of connections provided by connection portion 114 arelikewise determined by the desired functionality of the component 112,the corresponding elements that define component 112 to provide suchfunctionality, and the communication needs for such elements. Furtherstill, in some instances, one or more of the insulating portions 138,140, 142, and 144 is omitted. For example, as shown in the exemplaryembodiment of FIG. 4, insulating portion 144 has been omitted.

As noted above, in some instances the connection portion 114 is notspaced from the proximal end 110. For example, FIG. 5 illustrates anintravascular device 120 where the connection portion is positioned atthe proximal end 110 of the intravascular device. In such embodiments,the proximal end 110 of the intravascular device 120 may be defined byan insulating element (as shown by insulating portion 144 in FIG. 6) ora conductive element (as shown by conductive portion 136 in FIG. 7). Itshould also be noted that while the arrangements of FIGS. 3, 4, 5, and 6illustrate an insulating portion 138 as being positioned between theflexible elongate member 106 and the conductive portion 132, in someinstances the conductive portion 132 is positioned immediately adjacentto the elongate member without insulating portion 138. Accordingly, thevarious embodiments and associated methods of forming connectionportions for intravascular devices as discussed below may be implementedusing any combination of the arrangement of features described abovewith respect to FIGS. 1-7.

Referring now to FIGS. 8 and 9, shown therein are aspects of a connectorportion 150 of an intravascular device according to an embodiment of thepresent disclosure. As shown in FIG. 8, the connector portion 150includes conductive portions 152, 154 and insulating portions 156, 158.In that regard, the insulating portion 156 separates the conductiveportion 152 from the conductive portion 154. In some instances, theinsulating portion 158 separates the conductive portion 152 from one ormore other conductive portions (not shown) of the connector portion 150.A section 160 extending proximally from the connector portion 150 toanother section 162 that extends to a proximal end 164. The sections160, 162 have structures and arrangements as described above withrespect to sections 118, 120 in some instances.

Referring now to FIG. 9, shown therein is a partial cross-sectional sideview of part of the proximal connector portion 150. As shown, theinsulating portion 156 includes an outer surface 166. A plurality ofprojections 168 extend from the outer surface 166. Generally, theconnector portion 150 can include any number of projections 168 (or omitthe projections entirely), but in some embodiments the connector portion150 includes between 0 and 20 projections, with some particularembodiments having 0, 1, 5, and 8 projections. In some instances, theouter surface 166 has a generally cylindrical profile with a circularcross-section and the projections 168 also have a generally cylindricalprofile with a circular cross-section, but with an increased outerdiameter relative to the outer surface 166. In that regard, the outerdiameter of the projections is between about 0.0127 mm (0.0005″) andabout 0.0762 mm (0.003″) greater than the diameter of the outer surface166 in some instances, with some particular embodiments being 0.0127 mm(0.0005″), 0.019 mm (0.00075″), and 0.0254 mm (0.001″) greater.Accordingly, in some instances the outer surface 166 is recessed withrespect to the projections 168 by a distance between about 0.0127 mm(0.0005″) and about 0.0762 mm (0.003″), with some particular embodimentsbeing recessed a distance of 0.0127 mm (0.0005″), 0.019 mm (0.00075″),and 0.0254 mm (0.001″). Surface portions 170 transition the insulatingportion 156 between the outer surface 166 and the projections 168. Inthe illustrated embodiment, the surface portions 170 are taperedsurfaces that extend at an oblique angle with respect to a longitudinalaxis of the connector portion 150 between the outer surface 166 and theprojections 168. In other embodiments, surface portions 170 are omittedsuch that a step is created at the transition between outer surface 166and projections 168. In that regard, a surface extending between theouter surface 166 and the projections 168 extends perpendicular to thelongitudinal axis of the connector portion 150 in some instances.

In the illustrated embodiment, the projections 168 have a length 172along the longitudinal axis of the connector portion 150. The length 172is between about 0.0508 mm (0.002″) and about 1.27 mm (0.050″) in someinstances, with some particular embodiments having a length of 0.127 mm(0.005″), 0.254 mm (0.010″), and 0.508 mm (0.020″). Further, theprojections 168 are spaced from another by a distance 174 along thelongitudinal axis of the connector portion 150. The distance 174 can beany suitable distance and varies in some instances based on the numberof projections utilized, lengths of the projections utilized, and/orother factors. In that regard, it is understood that the projections 168may have equal spacing along the length of the connector portion 150,unequal spacing along the length of the connector portion 150, and/or acombination of equal and unequal spacing along the length of theconnector portion.

In some instances, the projections 168 of insulating portion 156 aresized and shaped to prevent bridging between the conductive portions 152and 154. In particular, the projections 168 are sized and shaped tominimize the impact of conductive liquid (e.g., blood or saline)bridging conductive portions 152 and 154 across insulating portion 156.Accordingly, in some particular embodiments the projections 168 are0.010″ wide such that the surface tension of any liquid in theportion(s) of the outer surface recessed relative to the projections(e.g., the portions defined by outer surface 166) will pull liquid offof the projection(s) 168 to minimize or eliminate any bridging.

The insulating portion 156 is positioned around a tubular member 176. Inthat regard, in some instances the diameter of an inner lumen of theinsulating portion 156 is sized and shaped such that it can be slidinglyadvanced over the tubular member 176. Accordingly, in some instances,the diameter of the inner lumen of the insulating portion 156 isapproximately equal to but slightly larger (e.g., between about 0.0005″and about 0.001″ larger) than the outer diameter of the tubular member176. Further, the tubular member 176 is configured to be positionedaround a core wire and one or more conductors. More specifically, thetubular member 176 includes an inner lumen that is sized and shaped toreceive the core wire and conductor(s). In the illustrated embodiment ofFIG. 9, for sake of clarity the core wire has been omitted. However, aconductor 178 extends within the lumen of the tubular member 176 asshown. A portion 180 of the conductor 178 extends through an opening ina sidewall of the tubular member 176. In that regard, the opening is incommunication with the lumen of the tubular member 176. As discussedbelow with respect to FIGS. 10-12, in some instances the opening is anelongated slot or slit extending along a length of the tubular member.

The portion 180 of the conductor 178 extending through the opening ofthe tubular member 176 is electrically coupled to the conductive portion154. In embodiments where the conductor 178 includes an insulating layeror sheath around a conductive core, a section of the insulating layermay be removed to expose a section of the conductive core. Any suitabletechniques can be utilized to electrically couple the conductor 178 tothe conductive portion 154, including soldering, laser welding, and/orother suitable technique. In some instances, the portion 180 of theconductor 178 is wrapped at least partially around the tubular member176 such that the soldering or other electrically coupling can beperformed away from the opening of the tubular member 176. In someinstances, the portion 180 is wrapped around the tubular member 176between about 90 degrees and about 270 degrees. As an example, in someimplementations the portion 180 of the conductor 178 is wrapped aroundthe tubular member such that the conductor 178 is soldered or otherwiseelectrically coupled to the conductive portion 154 opposite to theopening of the tubular member (i.e., approximately 180 degrees aroundthe circumference of the tubular member from the opening). With theportion 180 of conductor 178 wrapped around the tubular member 176, theconductor 178 will be positioned between the conductive portion 154 andthe insulating portion 156 such that a gap or spacing 182 is createdbetween the conductive portion 154 and the insulating portion 156. Insome instances, the spacing 182 is substantially equal to an outerdiameter of the conductor 178. Accordingly, in some implementations thespacing 182 is between about 0.0254 mm (0.001″) and about 0.0762 mm(0.003″). However, the spacing 182 is larger in other implementations.It should be noted, that while a single conductor 178 is illustrated inother instances a plurality of conductors may be passed through theopening in the tubular member 176 and electrically coupled to theconductive portion 154.

It is understood that arrangements similar to that shown in FIG. 9 canbe repeated for any number of conductive portions of the connectorportion 150. In that regard, a single tubular member 176 may extendalong the length of the connector portion 150 or a plurality of tubularmembers may be utilized along the length of the connector portion 150.In that regard, referring now to FIGS. 10-12, shown therein are variousembodiments of tubular members according to the present disclosure. Theone or more tubular members utilized within the connector portion 150have a structure similar to the embodiments of FIGS. 10-12 in someinstances.

Referring more specifically to FIG. 10, shown therein is a tubularmember 190. Tubular member 190 has a body 192 having a generallycylindrical profile with a central lumen extending along its length. Thebody 192 has a length 194 and a diameter 196. The length 194 variesgreatly between implementations and is dependent on various factors suchas the number of tubular members utilized for the connector, number ofconductive members utilized, size of the conductive members utilized,size of insulating members utilized, and/or other factors. In someinstances, the length 194 is between about 12.7 mm (0.5″) and about 76.2mm (3.0″), with some particular embodiments having a length of 41.9 mm(1.65″) and 33.0 mm (1.3″). In some implementations, the diameter 196 isbetween 0.0178 mm (0.0007″) and about 0.4572 mm (0.018″). In someinstances, the diameter of the inner lumen of the tubular member 190 isbetween about 0.0127 mm (0.0005″) and about 0.4318 mm (0.017″).Accordingly, in some instances the tubular member 190 has a wallthickness between an outer surface of the body 192 and the inner surfacedefining the lumen between about 0.0127 mm (0.0005″) and about 0.254 mm(0.01″), with some particular embodiments having a thickness of 0.0254mm (0.001″), 0.04064 mm (0.0016″), and 0.0508 mm (0.002″).

The tubular member 190 also includes an elongated opening 198 extendingalong the length of the body 192. In the illustrated embodiment of FIG.10, the opening 198 extends along the entire length 194 of the body 192.However, in other instances the opening extends along only a portion ofthe length of the body 192. The opening 198 is in communication with acentral lumen 200 of the tubular member 190. In that regard, the opening198 extends through a sidewall of the body 192 to provide access to thecentral lumen 200 of the tubular member 190. In the illustratedembodiment, the opening 198 has a substantially constant profile alongits length. In particular, the opening 198 has a width 202 that isconstant along the length of the opening 198. In some instances, thewidth 202 of the opening 198 is between about 0.0254 mm (0.001″) andabout 0.127 mm (0.005″), with some particular embodiments having a widthof about 0.0762 mm (0.003″). In other instances, the opening 198 has avariable profile along its length. In that regard, the size, shape,orientation, position around the circumference of the tubular member190, and/or other aspect of the profile of the opening 198 varies alongthe length of the opening.

Referring now to FIG. 11, shown therein is a tubular member 210according to another embodiment of the present disclosure. Tubularmember 210 has a body 212 having a generally cylindrical profile with acentral lumen extending along its length. The body 212 has a length 214and a diameter 216. The length 214 varies greatly betweenimplementations and is dependent on various factors such as the numberof tubular members utilized for the connector, number of conductivemembers utilized, size of the conductive members utilized, size ofinsulating members utilized, and/or other factors. In some instances,the length 214 is between about 12.7 mm (0.5″) and about 76.2 mm (3.0″),with some particular embodiments having a length of 41.9 mm (1.65″) and33.0 mm (1.3″). In some instances, the diameter 216 is between 0.0178 mm(0.0007″) and about 0.4572 mm (0.018″). In some instances, the diameterof the inner lumen of the tubular member 210 is between about 0.0127 mm(0.0005″) and about 0.4318 mm (0.017″). Accordingly, in some instancesthe tubular member 210 has a wall thickness between an outer surface ofthe body 212 and the inner surface defining the lumen between about0.0127 mm (0.0005″) and about 0.254 mm (0.01″), with some particularembodiments having a thickness of 0.0254 mm (0.001″), 0.04064 mm(0.0016″), and 0.0508 mm (0.002″).

The tubular member 210 also includes an elongated opening 218 extendingalong the length of the body 212. The opening 218 is in communicationwith a central lumen 220 of the tubular member 210. In that regard, theopening 218 extends through a sidewall of the body 212 to provide accessto the central lumen 220 of the tubular member 210. In the illustratedembodiment of FIG. 11, the opening 218 extends along a majority, butless than the entire length 214 of the body 212. In particular, theopening 218 extends along the body 212 a length 222 that is less thanlength 214. In some instances, the opening 218 extends along themajority of the length 214 of the body 212 such that only a smallsection of the body 212 does not include opening 218. For example, insome instances the section of the body that does not include opening 218extends along the length of the body a distance between about 1.27 mm(0.050″) and about 12.7 mm (0.50″), with some particular embodimentshaving a length of 4.57 mm (0.18″). In the illustrated embodiment, theopening 218 has a substantially constant profile along its length. Inparticular, the opening 218 has a width 224 that is constant along thelength of the opening 218. In some instances, the width 224 of theopening 218 is between about 0.0254 mm (0.001″) and about 0.127 mm(0.005″), with some particular embodiments having a width of about0.0762 mm (0.003″). In other instances, the opening 218 has a variableprofile along its length. In that regard, the size, shape, orientation,position around the circumference of the tubular member 210, and/orother aspect of the profile of the opening 218 varies along the lengthof the opening.

Referring now to FIG. 12, shown therein is a tubular member 230according to another embodiment of the present disclosure. Tubularmember 230 has a body 232 having a generally cylindrical profile with acentral lumen extending along its length. The body 232 has a length 234and a diameter 236. The length 234 varies greatly betweenimplementations and is dependent on various factors such as the numberof tubular members utilized for the connector, number of conductivemembers utilized, size of the conductive members utilized, size ofinsulating members utilized, and/or other factors. In some instances,the length 234 is between about 12.7 mm (0.5″) and about 76.2 mm (3.0″),with some particular embodiments having a length of 41.9 mm (1.65″) and33.0 mm (1.3″). In some instances, the diameter 236 is between 0.0178 mm(0.0007″) and about 0.4572 mm (0.018″). In some instances, the diameterof the inner lumen of the tubular member 230 is between about 0.0127 mm(0.0005″) and about 0.4318 mm (0.017″). Accordingly, in some instancesthe tubular member 230 has a wall thickness between an outer surface ofthe body 232 and the inner surface defining the lumen between about0.0127 mm (0.0005″) and about 0.254 mm (0.01″), with some particularembodiments having a thickness of 0.0254 mm (0.001″), 0.04064 mm(0.0016″), and 0.0508 mm (0.002″).

The tubular member 230 also includes an elongated opening 238 extendingalong the length of the body 232. The opening 238 is in communicationwith a central lumen 240 of the tubular member 230. In that regard, theopening 238 extends through a sidewall of the body 232 to provide accessto the central lumen 240 of the tubular member 230. In the illustratedembodiment of FIG. 12, the opening 238 extends along only a portion ofthe entire length 234 of the body 232. In particular, the opening 238extends along the body 232 a length 242 that is less than length 234. Insome instances, the length 242 of the opening 238 is between about 30%and about 99% of the total length of the body, with some particularembodiments having a length of about 40%, 50%, 75%, and 90% of the totallength of the body. In the illustrated embodiment, the opening 238 has asubstantially constant profile along its length. In particular, theopening 238 has a width 244 that is constant along the length of theopening 238. In some instances, the width 244 of the opening 238 isbetween about 0.0254 mm (0.001″) and about 0.127 mm (0.005″), with someparticular embodiments having a width of about 0.0762 mm (0.003″). Inother instances, the opening 238 has a variable profile along itslength. In that regard, the size, shape, orientation, position aroundthe circumference of the tubular member 230, and/or other aspect of theprofile of the opening 238 varies along the length of the opening.

The tubular members 190, 210, and 230 of FIGS. 10-12 may be formed ofany suitable material. In some embodiments, the tubular member is formedof an insulating material. In some particular embodiments, the tubularmember is formed of polyimide.

Referring now to FIGS. 13-19, shown therein are various aspects ofassembling a proximal connector portion, such as connector portion 150illustrated in FIGS. 8 and 9, according to an exemplary embodiment ofthe present disclosure. Referring initially to FIG. 13, a tubular member252 is positioned around a core 254 and a plurality of conductors 256,258, and 260. As shown, the core 254 and the plurality of conductors256, 258, and 260 extend proximally (to the right as viewed in FIG. 13)beyond the end of the tubular member 252. To facilitate easierillustration of the assembly steps, the core 254 is illustrated inphantom. In that regard, it is understood that in some instances theconductors 256, 258, and 260 are positioned around and runlongitudinally along the core 254. In some embodiments, the conductors256, 258, and 260 are wrapped (e.g., helically, spiral, weaved, orotherwise) around the core 254. In some embodiments, the conductors 256,258, and 260 extend parallel to the core 254 and parallel to oneanother. In some embodiments, portions of the conductors 256, 258, and260 are wrapped (e.g., helically, spiral, weaved, or otherwise) aroundthe core 254, while other portions of the conductors 256, 258, and 260extend parallel to the core 254. The tubular member 252 is positionedcoaxially around the core 254. In other embodiments, the core 254 isoffset with respect to a central longitudinal axis of the tubular member252. In some embodiments, the tubular member 252 is identical or similarto one or more of the embodiments described above with respect to FIGS.10-12.

Referring now to FIG. 14, an insulating member 260 is positioned aroundthe tubular member 252. As shown, the insulating member 260 ispositioned coaxially around the tubular member 252. In some embodiments,the insulating member 260 is advanced distally along the tubular member252 until the insulating member 260 is positioned adjacent the distalend of the tubular member 252. In that regard, in some instances thedistal end of the tubular member 252 is positioned adjacent to aproximal end of a flexible elongate member (such as flexible elongatemember 106), a proximal end of a conductive member, a proximal end of aninsulating member, and/or other component positioned of an intravasculardevice. In one embodiment, the insulating member 260 is advanced alongthe tubular member until a distal end of the insulating member 260contacts a proximal end of flexible elongate member 106 of anintravascular device.

Referring now to FIG. 15, a portion 262 of the conductor 256 is advancedthrough an opening in the tubular member 252, such as an opening similarto one or more of openings 198, 218, and 238 of tubular members 190,210, and 238 discussed above. In some embodiments, the portion 262 ofthe conductor 256 is wrapped at least partially around the tubularmember 252 such that the soldering or other electrically coupling can beperformed away from the opening of the tubular member 252. In someinstances, the portion 262 is wrapped around the tubular member 252between about 90 degrees and about 270 degrees. As an example, in someimplementations the portion 262 of the conductor 256 is wrapped aroundthe tubular member such that the conductor 256 can be soldered orotherwise electrically coupled to a conductive element positionedadjacent to and proximal to the portion 262 on an opposite of thetubular member 252 from the opening of the tubular member. Further, inembodiments where the conductor 256 includes an insulating layer orsheath around a conductive core, a section of the insulating layer isremoved to expose a section of the conductive core. In that regard, itis understood that a section of the portion 262 wrapped around thetubular member 252 includes an insulating layer or sheath in someinstances, while the insulating layer or sheath around another sectionof the portion 262 is removed to expose the underlying conductivematerial.

Referring now to FIG. 16, a conductive element 264 is positioned aroundthe tubular member 252. In some embodiments, the conductive element 264is advanced distally along the tubular member 252 until the conductiveelement 264 is positioned adjacent the proximal end of an insulatingmember 262. In that regard, in some instances the conductive element 264is advanced until it contacts the portion 262 of the conductor 256 suchthat the conductive element 264 is spaced from the insulating member 260by the portion 262. The portion 262 of the conductor 256 extendingthrough the opening of the tubular member 252 is electrically coupled tothe conductive element 264. Any suitable techniques can be utilized toelectrically couple the portion 262 of the conductor 256 to theconductive element 264, including soldering, laser welding, and/or othersuitable technique. In some instances, the wrapping of the portion 262of the conductor 256 around the tubular member 252 and/or removing aportion of an insulating layer or sheath is at least partially performedafter the conductive element 264 is positioned around the tubular member252.

Referring now to FIG. 17, an insulating member 266 is positioned aroundthe tubular member 252. As shown, the insulating member 266 ispositioned coaxially around the tubular member 252. The insulatingmember 266 is advanced distally along the tubular member 252 until theinsulating member 266 is positioned adjacent a proximal end of theconductive element 254. In some instances, the insulating member 266 isadvanced distally along the tubular member 252 until a distal end of theinsulating member 266 contacts a proximal end of the conductive element254.

Referring now to FIG. 18, a portion 268 of the conductor 258 is advancedthrough the opening in the tubular member 252. In some embodiments, theportion 268 of the conductor 258 is wrapped at least partially aroundthe tubular member 252 such that the soldering or other electricallycoupling can be performed away from the opening of the tubular member252. In some instances, the portion 268 is wrapped around the tubularmember 252 between about 90 degrees and about 270 degrees. As anexample, in some implementations the portion 268 of the conductor 258 iswrapped around the tubular member such that the conductor 258 can besoldered or otherwise electrically coupled to a conductive elementpositioned adjacent to and proximal to the portion 268 on an opposite ofthe tubular member 252 from the opening of the tubular member. Further,in embodiments where the conductor 258 includes an insulating layer orsheath around a conductive core, a section of the insulating layer isremoved to expose a section of the conductive core. In that regard, itis understood that a section of the portion 268 wrapped around thetubular member 252 includes an insulating layer or sheath in someinstances, while the insulating layer or sheath around another sectionof the portion 268 is removed to expose the underlying conductivematerial.

Referring now to FIG. 19, a conductive element 270 is positioned aroundthe tubular member 252. In some embodiments, the conductive element 270is advanced distally along the tubular member 252 until the conductiveelement 270 is positioned adjacent the proximal end of an insulatingmember 266. In that regard, in some instances the conductive element 270is advanced until it contacts the portion 268 of the conductor 258 suchthat the conductive element 270 is spaced from the insulating member 266by the portion 268. The portion 268 of the conductor 258 extendingthrough the opening of the tubular member 252 is electrically coupled tothe conductive element 270. Any suitable techniques can be utilized toelectrically couple the portion 268 of the conductor 258 to theconductive element 270, including soldering, laser welding, and/or othersuitable technique. In some instances, the wrapping of the portion 268of the conductor 258 around the tubular member 252 and/or removing aportion of an insulating layer or sheath is at least partially performedafter the conductive element 270 is positioned around the tubular member252.

Steps similar to those described in FIGS. 17-19 can be repeated toelectrically couple additional conductive elements to the plurality ofconductors extending along the core wire for any number of conductorsand/or conductive elements. Further, in some embodiments, multipleconductors of the plurality of conductors are coupled to a singleconductive element. For example, in one embodiment two conductors arecoupled to a single conductive element. In one such embodiment, the twoconductors are electrically coupled to the conductive element adjacentto one another. In other embodiments, the two conductors areelectrically coupled to the conductive element and spaced apart from oneanother. For example, one of the conductors is electrically coupled to adistal end of the conductive element, while the other conductor iselectrically coupled to a proximal end of the conductive element. In oneparticular implementation, one of the conductors is wrapped around thetubular member 252 adjacent a distal end of the conductive element,while the other conductor is wrapped around the tubular member adjacentto a proximal end of the conductive element.

In some instances, an adhesive is utilized to secure one or more of thecomponents in place. For example, in some instances, either during eachcomponent placement or after all components are placed and solderedtogether, the components are secured together with an adhesive or othersuitable material. In that regard, securing the components togetherserves to greatly reduce or eliminate potential problems with theresulting device. For example, in some implementations securing thecomponents together prevents relative rotation of the components thatcan lead to conductor breakage. As another example, the adhesive canalso fill any potential fluid paths that lead to internal bridging.Accordingly, in some instances, all internal gaps between a conductivebands/insulating spacers and the insulating tubular member or supportstructure below is filled with adhesive. Such an approach serves toeliminate any internal fluid pathways that may create a bridging effectand ensures that all components are fixedly secured to one another suchthat they won't mechanically shift, slip, and/or rotate relative toother components. Further, in some instances adhesive is also positionedbetween adjacent conductive bands and insulating spacers. In someembodiments, similar implementations of adhesives are used for the otherembodiments of the present disclosure described below.

Generally, the adhesive(s) can be any adhesive that provides adequatelocking of the components and/or gap filling capability to eliminateinternal fluid bridging. In some instances the adhesive is a UV curedadhesive. Further, in some instances, the adhesive also includes a heatcure and/or a secondary moisture cure to facilitate curing of areas thatcan't be UV cured. A flexible adhesive is used in some instances. One ormore of the following adhesive characteristics is taken intoconsideration in selecting the adhesive: adhesion and shear strength(e.g., to ensure that the component(s) can't rotate or slip, which wouldlikely result in a broken electrical connection and could allow fluidbridging); water resistance (e.g., water resistance adequate toeliminate potential for internal bridging of the electrical contacts);viscosity (e.g., viscosity low enough to allow the adhesive to fill inthe relatively small spaces that would allow for fluid migration. Itshould be noted, however, that adhesives that are slightly too viscousto wick into the gaps naturally can be forced into the assembly gapsusing pressurized application methods.); flexibility (e.g., to allow forthe typical manipulation of the proximal portion of the intravasculardevice during use. In particular, if adhesive positioned under theinsulating members cracks or otherwise separates due to bending or othermanipulation, internal fluid paths may open up between the conductivebands); and/or other suitable adhesive characteristics. Examples of thetypes of adhesives that can be used include: UV cured with secondaryheat cure (e.g., Dymax adhesives); UV cured, low viscosity siliconeswith secondary moisture cure (this type is preferable in someapplications because of the flexibility and water resistance);cyanoacrylates; and/or other known or future developed adhesives.

Referring now to FIGS. 20-22, shown therein are aspects of a connectorportion 300 of an intravascular device according to an embodiment of thepresent disclosure. As shown in FIG. 20, the connector portion 300includes conductive portions 302, 304 and insulating portions 306, 308.In that regard, the insulating portion 306 separates the conductiveportion 302 from the conductive portion 304. In some instances, theinsulating portion 308 separates the conductive portion 302 from one ormore other conductive portions (not shown) of the connector portion 300.A section 310 extending proximally from the connector portion 300 toanother section 312 that extends to a proximal end 314. The sections310, 312 have structures and arrangements as described above withrespect to sections 118, 120 and 160, 162 in some instances. Asdiscussed below, in some instances the connector portion 300 includes anelement that defines structures similar to those of tubular member 252and one or more of the insulating members 160, 166 in a single,integrally formed member. In that regard, a plurality of such elementsare utilized in some implementations to electrically couple a pluralityof conductive elements to a plurality of conductors as described belowin the context of FIGS. 29-34.

Referring now to FIGS. 21 and 22, shown therein are additional detailsof the proximal connector portion 300. As shown, the insulating portion306 includes an outer surface having a plurality of projections similarto insulating portion 156 described above. In that regard, the connectorportion 300 can include any number of projections (or omit theprojections entirely), but in some embodiments the connector portion 300includes between 1 and 20 projections, with some particular embodimentshaving 0, 1, 5, and 8. In some instances, the connector portion 300 hasa generally cylindrical profile with a circular cross-section and theprojections likewise have a generally cylindrical profile with acircular cross-section, but with an increased outer diameter relative tothe outer surface. In that regard, the outer diameter of the projectionsis between about 0.0127 mm (0.0005″) and about 0.0762 mm (0.003″)greater than the diameter of the outer surface of the connector portion300 in some instances, with some particular embodiments being 0.0127 mm(0.0005″), 0.019 mm (0.00075″), and 0.0254 mm (0.001″) greater.Accordingly, in some instances the outer surface of the connectorportion 300 is recessed with respect to the projections by a distancebetween about 0.0127 mm (0.0005″) and about 0.0762 mm (0.003″), withsome particular embodiments being recessed a distance of 0.0127 mm(0.0005″), 0.019 mm (0.00075″), and 0.0254 mm (0.001″). The projectionshave a length along the longitudinal axis of the connector portion 300about 0.0508 mm (0.002″) and about 1.27 mm (0.050″) in some instances,with some particular embodiments having a length of 0.127 mm (0.005″),0.254 mm (0.010″), and 0.508 mm (0.020″). Further, the projections arespaced from another by a distance along the longitudinal axis of theconnector portion 300. The spacing distance can be any suitable distanceand varies in some instances based on the number of projectionsutilized, lengths of the projections utilized, and/or other factors. Inthat regard, it is understood that the projections may have equalspacing along the length of the connector portion 300, unequal spacingalong the length of the connector portion 300, and/or a combination ofequal and unequal spacing along the length of the connector portion 300.

In some embodiments, the connector portion 300 includes transitionsbetween the outer surface and the projections. In the illustratedembodiment, the transitions are tapered surfaces that extend at anoblique angle with respect to a longitudinal axis of the connectorportion 300. In other embodiments, the transitions are omitted such thata step is created at the transition between outer surface and one ormore of the projections. In that regard, a surface extending between theouter surface and the projection outer surface extends perpendicular tothe longitudinal axis of the connector portion 300 in some instances.

As best seen in FIG. 21, the insulating portion 306 is integrally formedwith tubular portions 316 and 317. In that regard, in some instances thetubular portions 316 and 317 include structures and/or features similarto those described above with respect to tubular members 176, 190, 210,230, and 252. In that regard, the tubular portions 316 and 317 areconfigured to be positioned around a core wire and one or moreconductors in some instances. More specifically, in some embodiments thetubular portions 316 and 317 include an inner lumen that is sized andshaped to receive the core wire and conductor(s). In that regard, theinner lumen extends continuously through the insulating portion 306positioned between the tubular portions 316 and 317 in some embodiments.As shown, the tubular portion 316 is configured to be positioned withina distal section of conductive portion 304, while tubular portion 317 isconfigured to be positioned within a proximal section of conductiveportion 302. As shown in FIG. 22, a conductor 318 extends within thelumen of the tubular portion 317, the insulating portion 306, and thetubular portion 316 and extends through an opening 319 in a sidewall ofthe tubular portion 316. In that regard, the opening 319 is incommunication with the lumen. The opening 319 is an elongated slot orslit extending along a length of the tubular portion 316 in someinstances.

The conductor 318 extending through the opening 319 of the tubularportion 316 is electrically coupled to the conductive portion 304. Inembodiments where the conductor 318 includes an insulating layer orsheath around a conductive core, a section of the insulating layer maybe removed to expose a section of the conductive core. Any suitabletechniques can be utilized to electrically couple the conductor 318 tothe conductive portion 304, including soldering, laser welding, and/orother suitable technique. In some instances, the conductor 318 iswrapped at least partially around the tubular portion 316 such that thesoldering or other electrically coupling can be performed away from theopening 319 of the tubular portion 316. In some instances, the conductor318 is wrapped around the tubular portion 316 between about 90 degreesand about 270 degrees. As an example, in some implementations theconductor 318 is wrapped around the tubular portion 316 such that theconductor 318 is soldered or otherwise electrically coupled to theconductive portion 304 opposite to the opening 319 of the tubularportion 316 (i.e., approximately 180 degrees around the circumference ofthe tubular member from the opening). With the conductor 318 wrappedaround the tubular portion 316, the conductor 318 will be positionedbetween the conductive portion 304 and the insulating portion 306 suchthat a gap or spacing is created between the conductive portion 304 andthe insulating portion 306. In some instances, the spacing issubstantially equal to an outer diameter of the conductor 318.Accordingly, in some implementations the spacing is between about 0.0254mm (0.001″) and about 0.0762 mm (0.003″). However, the spacing is largerin other implementations. It should be noted, that while a singleconductor 318 is illustrated in other instances a plurality ofconductors may be passed through the opening 319 in the tubular portion316 and electrically coupled to the conductive portion 304.

It is understood that arrangements similar to that shown in FIGS. 21 and22 can be repeated for any number of conductive portions of theconnector portion 300. In that regard, in some instances a kitconsisting of a plurality of insulating portions and a plurality ofconductive portions is provided. A user can then assemble a connectorportion having a desired number of electrically isolated conductiveportions by positioning an insulating portion between a pair ofconductive portions. In some instances, the provided insulating portionsof the kit all have the same structure. In other instances, the kitincludes insulating portions with varying structures/features. Inparticular, in some instances the insulating portions has (a) a pair oftubular portions integrally formed therewith (e.g., similar to thearrangement of insulating portion 306 and tubular portions 316 and 317of FIGS. 21 and 22), (b) a single tubular portion integrally formedtherewith (e.g., an arrangement of insulating portion 306 that wouldinclude only one of the tubular portions 316 and 317, see also FIG. 28),or (c) no tubular portion integrally formed therewith (e.g., anarrangement of insulating portion 306 that does not include either ofthe tubular portions 316 and 317). In that regard, in some instances aninsulating portion with a single tubular portion integrally formedtherewith is particularly suitable for use in isolating a distal mostconductive portion of the connector portion 300 from the flexibleelongate member 106 of the intravascular device 102.

Referring now to FIGS. 23-25, shown therein are various stages of theformation of an insulating member according to an embodiment of thepresent disclosure. In that regard, FIG. 23 shows a tubular member 320.In some instances, tubular member 320 has a cylindrical outer profilewith an outer diameter between about 0.0178 mm (0.0007″) and about 3.0mm (0.118″), with some particular embodiments having an outer diameterof 0.3556 mm (0.014″), 0.3683 mm (0.0145″) and 0.4572 (0.018″). Further,in some embodiments, the tubular member 320 has an inner lumen extendingalong its length. In some instances, the inner lumen has a circularcross-sectional profile with a diameter less than the outer diameter. Inthat regard, the diameter of the lumen is between about 0.0508 mm(0.002″) and about 0.254 mm (0.01″) less than the outer diameter of thetubular member 320 in some instances, with some particular embodimentsbeing between about 0.1016 mm (0.004″) and 0.127 mm (0.005″) less.Generally, the tubular member 320 can have any length as the tubularmember 320 may be cut, ablated, and/or otherwise reduced in length orseparated into multiple pieces based on a desired length for theparticular insulating member being formed in accordance with the presentdisclosure. In some implementations, the desired length of theinsulating member is between about 12.7 mm (0.5″) and about 76.2 mm(3.0″), with some particular embodiments having a length of 41.9 mm(1.65″) and 33.0 mm (1.3″). In that regard, in FIGS. 23-25 the tubularmember 320 is illustrated as having already been processed to thedesired length. The tubular member 320 is formed of an insulatingmaterial in some embodiments. For example, in some particularembodiments the tubular member 320 is formed of polyimide.

Referring more specifically to FIG. 24, portions of the tubular member320 that are to be removed to create the desired structure of theinsulating member are identified. In that regard, dashed lines 322 and324 illustrate portions of the tubular member that will be removedcompletely. In the illustrated embodiment, the dashed lines 322 and 324are indicative of a circumferential removal of material about the outerdiameter of the tubular member 320. Accordingly, as shown, removal ofthe material indicated by lines 322 and 324 serves to provide thetubular member with outer portions having a reduced diameter withrespect to a central portion, where material is not removed. In thatregard, in some instances the lines 322 and 324 are positioned insidethe outer diameter of the tubular member 320, such that the resultingtubular portions with reduced diameters have outer diameters that arebetween 0.0254 mm (0.001″) and about 0.1 mm (0.01″) less than the outerdiameter of the tubular member 320, with some particular embodimentsbeing between about 0.0508 mm (0.002″) and 0.127 mm (0.005″) less.Dashed lines 326 represent a portion of the tubular member 320 wherematerial will be removed through one sidewall of the tubular member 320.In other words, material will be removed from the outer surface untilthe inner lumen of the tubular member is accessed for the arearepresented by dashed lines 326. The portion of the sidewall of thetubular member 320 opposite lines 326 is not removed in the illustratedembodiment. However, in other instances, a portion, portions, or all ofthe sidewall of the tubular member 320 opposite lines 326 is removed. Inthat regard, in some embodiments, opposed openings are created withinthe opposing sidewalls of the tubular member 320 along the path definedby lines 326. The material of tubular member 320 to be removed, asindicated by lines 322, 324, and 326, can be removed using any suitabletechnique for the particular material. Accordingly, in some instancesthe material is laser ablated.

Referring now to FIG. 25, shown therein is an insulating member 330formed by removing the material along lines 322, 324, and 326 asdescribed above. As shown, the insulating member 330 includes a tubularportion 332 (defined by the removal of material along lines 322), atubular portion 334 that includes an opening 336 extending along itslength (defined by the removal of material along lines 324 and 326), andan insulating portion 338 positioned between tubular portions 332 and334. In that regard, the insulating portion 338 has the same outerdiameter as tubular member 320 in some instances. In other instances, anouter portion of the tubular member 320 is also removed to defineinsulating portion 338 as well.

Referring now to FIGS. 23, 26, and 27, shown therein are various stagesof the formation of an insulating member according to another embodimentof the present disclosure. Again, FIG. 23 shows tubular member 320 thatis utilized to form the insulating member. Referring more specificallyto FIG. 26, portions of the tubular member 320 that are to be removed tocreate the desired structure of the insulating member are identified. Inthat regard, dashed lines 342, 344, and 346 are substantially similar tolines 322, 324, and 326, respectively, described above. Accordingly,these portions will not be discussed in detail again. However, theplurality of dashed lines 348 illustrate portions of the tubular memberthat will be removed to define projections of an insulating portion ofthe insulating member. In that regard, the dashed lines 348 of theillustrated embodiment generally have a profile configured to define aplurality of projections having structures similar to those ofprojections 168 illustrated in FIG. 9. However, it is understood thatthe dashed lines 348 can be configured to define any desired projectionshape and/or transition type between the projection and other portionsof the insulating member. In the illustrated embodiment, the dashedlines 348 are indicative of a circumferential removal of material aboutthe outer diameter of the tubular member 320.

Accordingly, as shown in FIG. 27, removal of the material indicated bylines 348 serves to provide the tubular member 350 with outer portions351 having a reduced diameter with respect to the resulting projections352 where material is not removed (or removed to a lesser extent). Inthat regard, in some instances the lines 348 have a depth such that theresulting portions 351 with reduced diameters have outer diameters thatare between 0.0127 mm (0.0005″) and about 0.0762 mm (0.003″) less thanthe outer diameter of the projections 352, with some particularembodiments being 0.0127 mm (0.0005″), 0.019 mm (0.00075″), and 0.0254mm (0.001″) less. In that regard, the insulating member 350 formed byremoving the material along lines 342, 344, 346, and 348 as describedabove includes a tubular portion 353 (defined by the removal of materialalong lines 342), a tubular portion 354 that includes an opening 356extending along its length (defined by the removal of material alonglines 344 and 346), and an insulating portion 358 positioned betweentubular portions 353 and 354 (defined by the removal of material alonglines 348). In that regard, the projections 352 of insulating portion358 have the same outer diameter as tubular member 320 in someinstances. In other instances, an outer portion of the tubular member320 is also removed to define projections 352 of insulating portion 358as well.

Referring now to FIG. 28, shown therein is an insulating member 360according to another embodiment of the present disclosure. As shown, theinsulating member 360 includes an insulating portion 362 and a tubularportion 364. The tubular portion 364 has a reduced profile relative tothe insulating portion 362 and includes an opening 366 extending alongits length. In some instances, the insulating portion 362 and thetubular portion 364 are similar to insulating portions and tubularportions, respectively, of other embodiments of the present disclosure.However, as shown, the insulating member 360 includes only one tubularportion such that the insulating portion 362 defines one end of theinsulating member 360 and the tubular portion 364 defines the opposingend of the insulating member. In some implementations, insulatingmembers having structures similar to insulating member 360 are utilizedfor the distal most and/or proximal most insulating members of aconnector portion of an intravascular device.

Referring now to FIGS. 29-34, shown therein are various aspects ofassembling a proximal connector portion, such as connector portion 300illustrated in FIGS. 20-22, according to an exemplary embodiment of thepresent disclosure. Referring initially to FIG. 29, an insulating member370 is positioned around a core 254 and a plurality of conductors 256,258, and 260. As shown, the core 254 and the plurality of conductors256, 258, and 260 extend proximally (to the right as viewed in FIG. 29)beyond the end of the insulating member 370. Again, to facilitate easierillustration of the assembly steps, the core 254 is illustrated inphantom. In that regard, it is understood that in some instances theconductors 256, 258, and 260 are positioned around and runlongitudinally along the core 254. In some embodiments, the conductors256, 258, and 260 are wrapped (e.g., helically, spiral, weaved, orotherwise) around the core 254. In some embodiments, the conductors 256,258, and 260 extend parallel to the core 254 and parallel to oneanother. In some embodiments, portions of the conductors 256, 258, and260 are wrapped (e.g., helically, spiral, weaved, or otherwise) aroundthe core 254, while other portions of the conductors 256, 258, and 260extend parallel to the core 254. The insulating member 370 is positionedcoaxially around the core 254. In other embodiments, the core 254 isoffset with respect to a central longitudinal axis of the insulatingmember 370. In some embodiments, the insulating member 370 is identicalor similar to one or more of the embodiments described above withrespect to FIG. 21, 22, 25, 27, or 28. In the illustrated embodiment,insulating member 370 is similar to insulating member 360 of FIG. 28.

Referring now to FIG. 30, a portion 372 of the conductor 256 is advancedthrough an opening in the tubular member 370, such as an opening similarto one or more of openings 319, 336, 356, and 366 discussed above. Insome embodiments, the portion 372 of the conductor 256 is wrapped atleast partially around a portion of insulating member 370 such that thesoldering or other electrically coupling can be performed away from theopening. In some instances, the portion 372 is wrapped around theinsulating member 370 between about 90 degrees and about 270 degrees. Asan example, in some implementations the portion 372 of the conductor 256is wrapped around the tubular member such that the conductor 256 can besoldered or otherwise electrically coupled to a conductive elementpositioned adjacent to and proximal to an insulating portion of theinsulating member 370 on an opposite of the insulating member 370 fromthe opening. Further, in embodiments where the conductor 256 includes aninsulating layer or sheath around a conductive core, a section of theinsulating layer is removed to expose a section of the conductive core.In that regard, it is understood that a section of the portion 372wrapped around the tubular portion of the insulating member 370 includesan insulating layer or sheath in some instances, while the insulatinglayer or sheath around another section of the tubular portion is removedto expose the underlying conductive material.

Referring now to FIG. 31, a conductive element 374 is positioned aroundthe tubular portion of insulating member 370. In some embodiments, theconductive element 374 is advanced distally along the tubular portion ofinsulating member 370 until the conductive element 374 is positionedadjacent the proximal end of the insulating portion of insulating member370. In that regard, in some instances the conductive element 374 isadvanced until it contacts the portion 372 of the conductor 256 suchthat the conductive element 374 is spaced from the insulating portion ofinsulating member 370 by the portion 372. The portion 372 of theconductor 256 extending through the opening of the tubular portion ofthe insulating member 370 is electrically coupled to the conductiveelement 374. As noted previously, any suitable techniques can beutilized to electrically couple the portion 372 of the conductor 256 tothe conductive element 374, including soldering, laser welding, and/orother suitable technique. In some instances, the wrapping of the portion372 of the conductor 256 around the tubular portion of the insulatingmember 370 and/or removing a portion of an insulating layer or sheath isat least partially performed after the conductive element 374 ispositioned around the tubular portion of the insulating member 370.

Referring now to FIG. 32, an insulating member 376 is positioned arounda core 254 and conductors 258 and 260. The insulating member 376 ispositioned coaxially around the core 254. In other embodiments, the core254 is offset with respect to a central longitudinal axis of theinsulating member 376. In some embodiments, the insulating member 376 isidentical or similar to one or more of the embodiments described abovewith respect to FIG. 21, 22, 25, 27, or 28. In the illustratedembodiment, insulating member 376 is similar to insulating member 330 ofFIG. 25. The insulating member 376 is advanced distally over the core254 until an insulating portion of the insulating member 376 ispositioned adjacent to a proximal end of the conductive element 374. Insome instances, the insulating member 376 is advanced distally along thecore 254 until a distal end of the insulating portion of the insulatingmember 376 contacts a proximal end of the conductive element 374. In theillustrated embodiment, a distal tubular portion of the insulatingmember 376 extends within conductive element 374. As shown, the distalend of the distal tubular portion of the insulating member 376 is spacedfrom the proximal end of the proximal tubular portion of insulatingmember 370, represented by space 378. Generally, the length of space 378along the longitudinal axis of the core 254 is between about 0.127 mm(0.005″) and about 5.08 mm (0.20″), with some particular embodimentshaving lengths of 1.27 mm (0.050″), 2.54 mm (0.10″), and 3.81 mm(0.150″). In that regard, the length of space 378 is representative ofthe distance between the distal end of the distal tubular portion of theinsulating member 376 and the proximal end of the proximal tubularportion of insulating member 370. In some instances, there is no spacebetween the distal end of the distal tubular portion of the insulatingmember 376 and the proximal end of the proximal tubular portion ofinsulating member 370. In other words, the insulating member 376 isadvanced until the distal end of the distal tubular portion of theinsulating member 376 contacts the proximal end of the proximal tubularportion of insulating member 370.

Referring now to FIG. 33, a portion 380 of the conductor 258 is advancedthrough an opening in the proximal tubular portion of insulating member376, such as an opening similar to one or more of openings 319, 336,356, and 366 discussed above. In some embodiments, the portion 380 ofthe conductor 258 is wrapped at least partially around a portion ofinsulating member 376 such that the soldering or other electricallycoupling can be performed away from the opening. In some instances, theportion 380 is wrapped around the insulating member 376 between about 90degrees and about 270 degrees. As an example, in some implementationsthe portion 380 of the conductor 258 is wrapped around the tubularmember such that the conductor 258 can be soldered or otherwiseelectrically coupled to a conductive element positioned adjacent to andproximal to an insulating portion of the insulating member 376 on anopposite of the insulating member 376 from the opening. Further, inembodiments where the conductor 256 includes an insulating layer orsheath around a conductive core, a section of the insulating layer isremoved to expose a section of the conductive core. In that regard, itis understood that a section of the portion 380 wrapped around thetubular portion of the insulating member 376 includes an insulatinglayer or sheath in some instances, while the insulating layer or sheatharound another section of the tubular portion is removed to expose theunderlying conductive material.

Referring now to FIG. 34, a conductive element 382 is positioned aroundthe proximal tubular portion of insulating member 376. In someembodiments, the conductive element 382 is advanced distally over thecore 254 and along the proximal tubular portion of insulating member 376until the conductive element 382 is positioned adjacent the proximal endof the insulating portion of insulating member 376. In that regard, insome instances the conductive element 382 is advanced until it contactsthe portion 380 of the conductor 258 such that the conductive element382 is spaced from the insulating portion of insulating member 376 bythe portion 380. The portion 380 of the conductor 258 extending throughthe opening of the proximal tubular portion of the insulating member 376is electrically coupled to the conductive element 382. As notedpreviously, any suitable techniques can be utilized to electricallycouple the portion 380 of the conductor 258 to the conductive element382, including soldering, laser welding, and/or other suitabletechnique. In some instances, the wrapping of the portion 380 of theconductor 258 around the proximal tubular portion of the insulatingmember 376 and/or removing a portion of an insulating layer or sheath isat least partially performed after the conductive element 382 ispositioned around the proximal tubular portion of the insulating member376.

Steps similar to those described in FIGS. 32-34 can be repeated toelectrically couple additional conductive elements to the plurality ofconductors extending along the core wire for any number of conductorsand/or conductive elements. In some embodiments, an insulating memberhaving a single tubular portion integrally formed with an insulatingportion is utilized adjacent the proximal most conductive element. Inthat regard, in some instances, the tubular portion is arranged distallyof the insulating portion, such that the tubular portion extends withinthe proximal most conductive element and the insulating portion servesas a proximal boundary of the connector portion. Further, in someembodiments, multiple conductors of the plurality of conductors arecoupled to a single conductive element.

Persons skilled in the art will also recognize that the apparatus,systems, and methods described above can be modified in various ways.Accordingly, persons of ordinary skill in the art will appreciate thatthe embodiments encompassed by the present disclosure are not limited tothe particular exemplary embodiments described above. In that regard,although illustrative embodiments have been shown and described, a widerange of modification, change, and substitution is contemplated in theforegoing disclosure. It is understood that such variations may be madeto the foregoing without departing from the scope of the presentdisclosure. Accordingly, it is appropriate that the appended claims beconstrued broadly and in a manner consistent with the presentdisclosure.

What is claimed is:
 1. An intravascular device, comprising: a flexibleelongate member; at least one sensing element coupled to a distalsection of the flexible elongate member; and a connection portioncoupled to a proximal section of the flexible elongate member, theconnection portion including: a first insulating member positionedaround a plurality of conductors and a core member such that theplurality of conductors and the core member are at least partiallypositioned within a lumen of the first insulating member, the firstinsulating member having a first portion with a first diameter, a secondportion with a second diameter less than the first diameter, and anopening extending along a length of the first insulating member incommunication with the lumen; and a first conductive member positionedaround the second portion of the first insulating member, wherein afirst of the plurality of conductors extends radially through theopening in the first insulating member such that a portion of the firstof the plurality of conductors is positioned between an axial end of thefirst insulating member and an axial end of the first conductive memberand is electrically coupled to the first conductive member.
 2. Theintravascular device of claim 1, wherein the opening of the firstinsulating member extends along only a portion of the length of thefirst insulating member.
 3. The intravascular device of claim 2, whereinthe opening of the first insulating member extends along the secondportion of the first insulating member.
 4. The intravascular device ofclaim 1, wherein the first conductive member has an outer diameter equalto the first diameter.
 5. The intravascular device of claim 1, furthercomprising a second insulating member positioned around the plurality ofconductors, less the first of the plurality of conductors, and the coremember such that the plurality of conductors, less the first of theplurality of conductors, and the core member are at least partiallypositioned within a lumen of the second insulating member, wherein afirst portion of the second insulating member has a third diameter, asecond portion of the second insulating member has a fourth diameterless than the third diameter, and a third portion of the secondinsulating member has a fifth diameter less than the third diameter. 6.The intravascular device of claim 1, wherein the at least one sensingelement includes a pressure sensor.
 7. The intravascular device of claim1, wherein the first portion of the first insulating member includes aplurality of projections.
 8. The intravascular device of claim 1,wherein the portion of the first of the plurality of conductors iswrapped around the first insulating member between 90 degrees and 270degrees.
 9. An intravascular device, comprising: a first insulatingmember positioned around a plurality of conductors and a core membersuch that the plurality of conductors and the core member are at leastpartially positioned within a lumen of the first insulating member, thefirst insulating member having a first portion with a first diameter, asecond portion with a second diameter less than the first diameter, andan opening extending along a length of the first insulating member incommunication with the lumen; a first conductive member positionedaround the second portion of the first insulating member, wherein afirst of the plurality of conductors extends radially through theopening in the first insulating member such that a portion of the firstof the plurality of conductors is positioned between an axial end of thefirst insulating member and an axial end of the first conductive memberand is electrically coupled to the first conductive member; and a secondinsulating member positioned around the plurality of conductors, lessthe first of the plurality of conductors, and the core member such thatthe plurality of conductors, less the first of the plurality ofconductors, and the core member are at least partially positioned withina lumen of the second insulating member, wherein a first portion of thesecond insulating member has a third diameter, a second portion of thesecond insulating member has a fourth diameter less than the thirddiameter, and a third portion of the second insulating member has afifth diameter less than the third diameter, wherein the third portionof the second insulating member is positioned at least partially withinthe first conductive member.
 10. The intravascular device of claim 9,further comprising a second conductive member positioned around thesecond portion of the second insulating member such that the firstportion of the second insulating member is positioned between the firstconductive member and the second conductive member.
 11. Theintravascular device of claim 10, wherein a second of the plurality ofconductors is electrically coupled to the second conductive member. 12.The intravascular device of claim 11, wherein the second of theplurality of conductors extends through an opening extending along alength of the second insulating member in communication with the lumenof the second insulating member.
 13. The intravascular device of claim9, wherein the portion of the first of the plurality of conductors iswrapped around the first insulating member between 90 degrees and 270degrees.
 14. A method of assembling an intravascular device, comprising:positioning a first tubular member around a plurality of conductors anda core member adjacent a proximal section of a flexible elongate membersuch that the plurality of conductors and the core member are at leastpartially positioned within a lumen of the first tubular member, thefirst tubular member including a first portion with a first diameter, asecond portion with a second diameter less than the first diameter, andan opening extending along a length of the first tubular member incommunication with the lumen; advancing a first of the plurality ofconductors through the opening of the first tubular member such that aportion of the first of the plurality of conductors extends radiallybeyond the opening; positioning a first conductive member around thesecond portion of the first tubular member such that the portion of thefirst of the plurality of conductors is positioned between an end of thefirst tubular member and an axial end of the first conductive member;electrically coupling first of the plurality of conductors to the firstconductive member; and electrically coupling the first of the pluralityof conductors to at least one sensing element coupled to a distalsection of the flexible elongate member, the first of the plurality ofconductors extending along a length of the flexible elongate memberbetween the at least one sensing element and the first conductivemember.
 15. The method of claim 14, further comprising: positioning afirst insulating member around the first tubular member adjacent to thefirst conductive member; positioning a second conductive member aroundthe first tubular member adjacent to the first insulating member suchthat the first insulating member is positioned between the first andsecond conductive members; and electrically coupling a second of theplurality of conductors to the second conductive member.
 16. The methodof claim 15, further comprising advancing the second of the plurality ofconductors through the opening of the first tubular member.
 17. Themethod of claim 15, further comprising: positioning a second insulatingmember around the first tubular member adjacent to the second conductivemember; positioning a third conductive member around the first tubularmember adjacent to the second insulating member such that the secondinsulating member is positioned between the second and third conductivemembers; and electrically coupling a third of the plurality ofconductors to the third conductive member.
 18. The method of claim 14,further comprising: positioning a second tubular member around theplurality of conductors, less the first of the plurality of conductors,and the core member such that the plurality of conductors, less thefirst of the plurality of conductors, and the core member are at leastpartially positioned within a lumen of the second tubular member,wherein a first portion of the second tubular member has a thirddiameter, a second portion of the second tubular member has a fourthdiameter less than the third diameter, and a third portion of the secondtubular member has a fifth diameter less than the third diameter. 19.The method of claim 18, wherein the second tubular member is positionedaround the plurality of conductors, less the first of the plurality ofconductors, and the core member such that the third portion of thesecond tubular member is positioned at least partially within the firstconductive member.
 20. The method of claim 18, further comprisingpositioning a second conductive member around the second portion of thesecond tubular member such that the first portion of the second tubularmember is positioned between the first conductive member and the secondconductive member.
 21. The method of claim 20, further comprisingelectrically coupling a second of the plurality of conductors to thesecond conductive member.
 22. The method of claim 14, wherein the atleast one sensing element includes a pressure sensor.
 23. The method ofclaim 14, further comprising wrapping the portion of the first of theplurality of conductors around the first tubular member between 90degrees and 270 degrees.